I just rebuilt these forks. They are from an 07 ZX6R. I can't get the bolt in the bottom of the fork, the one that holds the damper, to tighten all the way. It threads into the damper fine when the fork is apart. It just wont hold torque. It threads in all the way, it just keeps spinning and spinning at the end. I noticed that the inside of the damper where the threads are was spinning when I tried to tighten it outside the fork. I tried re-staking it, and it seemed ot hold, but still, the bolt spins and spins. Any ideas? One fork went together perfectly, the other is doing this.
You need something to hold the fork cylinder so that you can tighten that bolt. This is what the '03's call for so I'm sure it's going to be about the same. You can probably fabricate something that will work just as well as what is used in the manual. Take a look on the left side of the home page, there is a section for manuals and will show the tool that I am referring to.
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